Container feed and in-line filler system

ABSTRACT

A container feed and in-line filler system comprises an organizer including a conveyor and guide rails and a stop for organizing containers to be filled with a flowable material into rows and files, and a filler rack carried above the organizer whereby empty containers being organized are filled before being transferred out of the organizer.

BACKGROUND

1. Field of the Invention

The invention relates generally to packaging systems for fillingcontainers with flowable materials. More particularly, the inventionrelates to container feed apparatus and container filling apparatus foruse in a product packaging line.

2. Description of Related Art

In conventional packaging processes where bottles or other containersare filled with flowable materials there is usually provided a containerfeed apparatus which organizes containers for introduction onto theline. For example containers from reshippers are deposited onto a feedtable adjacent a series of parallel rails which organize the containersinto files. By another means, for example pushing the containers againsta transverse rail, they are organized into rows. In one arrangement aconveyor moving in a direction transverse to the organizing railstransfers the containers out onto the line one row at a time. The nextbottle of each file then moves onto the transverse conveyor and upagainst the transverse rail, ready for transfer out onto the line.

Elsewhere on the line a filler awaits the empty containers and fillsthem in turn. In order to speed production fillers are constructed so asto fill multiple containers in each filling cycle. As is well known,such parallel processing increases production speed. However, containerscoming from the feeder conventionally have to wait before transferringinto the filler, and there is a required time for the containers totransfer out of the filler. The containers then are transferred tocapping and labeling apparatus, as required.

SUMMARY OF THE INVENTION

It has been recognized that the time required for the empty containersto transfer in, and the filled containers to transfer out, of a fillingstation on a production line can be saved by combining the fillingoperation with the container feed operation. Since the containers are“stacked-up” in the feed operation in any case, so that they may beorganized by row and/or file, it is possible to fill the containers atthis location with appropriate configuration and control of the feedapparatus combined with fill apparatus placed over the feeder.

The invention accordingly provides a container feed and in-linecontainer filler system comprising a support frame and a conveyorcarried by the frame. The conveyor moves randomized containers in afirst direction from a first side toward a second side, this can be inindex motion. An organizer, supported by the frame and furthercomprising a set of guide rails which line up containers in files as thecontainers move in the first direction, is provided; and, a stoppreventing further motion of the containers in the first directioncooperating with the guide rails and the conveyor to pack the containersinto rows. A filling station is provided above the organizer, thefilling station being adapted to fill a row of containerssimultaneously. Also, a transverse conveyor intermediate the end railand the second side of the conveyor, supported by the frame, isprovided. Using this apparatus containers are organized into ranks androws and filled in the organizer. The filled containers push theforwardmost containers onto the transverse conveyor as the conveyor isindexed.

The apparatus in a more detailed aspect can further comprise a feedtable for receiving randomized containers adjacent the first end of theconveyor. At the second end a transverse conveyor and an end rail can beprovided to receive the filled containers and transfer them to labelingand/or capping operations.

Further, gates can be provided which act as the stop to organize thecontainers into rows. The gates can be made to open and close incoordinated movement with the conveyor to insure the first andsuccessive rows of containers are filled before transferring out ontothe line. Alternatively an end rail adjacent the transverse conveyor canact as the stop, the containers stacking up against the end rail andthereby being organized into rows back through the organizer.

In a further detailed aspect many fillers can be arranged in line acrossthe organizer which can be constructed so that many files of containersare created and organized into rows. The organizer can be madeadjustable to accommodate different sized containers. The system can beprovided with sufficient space between the fillers and the transverseconveyor that filled containers provide sufficient resistance to slidingwith respect to the conveyor that they push the forwardmost row ofcontainers onto the transverse conveyor.

In another detailed aspect the system can include redundant fluid fillerfeed pumps and manifolds so that one can be serviced while the other isin operation, facilitating rapid changeover from filling one product toanother. Further, the location of the fillers and the stops can be madeadjustable, which in combination with the adjustability of the organizerguide rails and end rail simplifies changeovers.

In a further more detailed aspect a microprocessor-based control systemcan be incorporated allowing presetting and storage for later use ofparameters for filling of one or a number of different products and/orcontainer types.

Further advantages obtained by the invention will be apparent withreference to the following detailed description, taken together with theappended drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

So that the way the advantages and objects of the invention are obtainedcan be more fully described, a particular and specific embodiment orembodiments of the invention are illustrated in the appended drawings.Although one or several embodiments of the invention are illustrated, itwill be understood that they are only one or more presently preferredembodiments. The invention is not limited to these specific embodimentsin its scope, and the invention will be described and explained withadditional specificity through the use of the accompanying drawings inwhich:

FIG. 1 is a side elevation view, partially in section, of a containerfeed/filler apparatus in accordance with the invention;

FIG. 2 is a top view of the apparatus shown in FIG. 1;

FIG. 3 is an end view taken along line 3—3 in FIG. 1 of the apparatusshown in FIG. 1.

FIG. 4 is an elevation view of a gate portion of the apparatus showingthe gates closed;

FIG. 5 is an elevation view of the gate portion shown in FIG. 4 with thegates in an open position;

FIG. 6 is a side elevation view of the gate portion shown in FIG. 4;

FIG. 7 is a schematic block diagram illustrating the principles ofoperation of an exemplary control system for the apparatus shown in theFIGS. 1-6;

FIG. 8 is a side elevation view of another embodiment of the invention;and

FIG. 9 is a top view of the apparatus shown in FIG. 8.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

With reference to FIG. 1 of the drawings, a combination container feedand in-line filler system 10 (hereinafter “feed/filler”) in accordancewith the invention and adapted for food or chemical product packaginguse for example facilitates loading empty containers onto a feeder table12 supported by a frame 13 formed of stainless or mild steel, whichcontainers are carried by a conveyor 14 into a set of guide rails 16which cooperate with gates 17 and an end rail 18 to organize thecontainers for filling and subsequent transfer out of the feed/filler bya transverse conveyor 20. The apparatus of the feed/filler system isadapted to bolt up to an existing 4½ inch conveyor for example, but thesize of the transverse conveyor can be modified depending on theapplication and the apparatus can be sized to bolt up to smaller orlarger conveyor lines. A chain idler (not shown) is provided tofacilitate this connection. The apparatus is painted with an approvedpaint for food handling equipment or can be unpainted where formed ofstainless steel or of a polymeric resin for example, which materialstolerate repeated wash-downs.

The conveyor 14, guide rails 16, gates 17 and end rail 18 together forman organizer system that takes randomized containers, for examplebottles 22 and organizes them into files and rows as they move from afirst side 21 toward a second side 23 of the feed/filler 10. The guiderails guide the containers into files, and the conveyor pushing thecontainers up against the end rail and/or gates organizes them intorows. The rows are sequentially moved out of the feed/filler by means ofthe conveyor pushing them onto the transverse conveyor 20 which thentakes them in either of the two directions transverse to the conveyor,depending on how the particular installation of the system. The conveyormoves in index fashion, propelled by an air cylinder 24 adjustablylinked to a lever 26 connected by a ratchet and pawl mechanism (notshown) to a hub 28 operatively connected to a conveyor drive spindle 30by a pulley 32 and link belt 34. The link belt is tensioned by an idler36. Adjustability in where the cylinder is linked to the lever,facilitated by a slot 38 and tightenable slider 40, allows adjustabilityin the amount of rotational motion imparted to the hub, and hencetranslational motion imparted to the conveyor, with each stroke of theair cylinder. The cylinder is reciprocated by a controlled valvingarrangement (not shown) in fluid communication with the cylinder 24 anda source of compressed air (not shown). Because of the adjustability inthe stroke of the air cylinder different sized containers can beorganized for sequential filling into rows as the conveyor indexes themtoward the end rail 18, causing them to stack up in the organizer backthrough the guide rails 16.

Other means of driving the conveyor 14 can be employed, for example astepper motor (not shown) could be used, or another means such as ahydraulic motor (not shown) in a servo-controlled valved hydrauliccircuit, for example alternately allowing or preventing fluid flow whichallows or prevents motor actuation by being placed intermittently influid communication or denied communication with a source of pressurizedfluid and/or a fluid sink. Other servomechanisms and actuation meanscould alternatively be used, as will be appreciated by those skilled inthe art.

The conveyor 14 in the illustrated embodiment is formed of polymer resinlinks and is conventionally tensioned using a conveyor idler spindle 42adjacent the drive spindle 30. The conveyor belt is one of the manyFDA-approved conveyor belts widely commercially available and isapproximately 36 inches wide in the illustrated embodiment. The conveyorbelt alternatively can be formed of stainless steel links or wire mesh,or can be a composite design using fiber reinforced elastomeric materialfor example. As will be appreciated by those skilled in the art, thedesired frictional engagement between the conveyor belt and thecontainers to be filled can be altered by selecting an appropriate belttype.

The conveyor belt 14 is supported by a plate 44 rigidized by stiffeners46 disposed underneath. The plate can be covered by a low frictionmaterial. A lip 48, formed of a low friction material, is disposed so asto support a sharp turn of the conveyor back under the plate 44 to thedrive spindle 30. This configuration allows the conveyor 14 to closelyabut the transverse conveyer 20 at the second side 23 of the feed/fillerso that containers will slide smoothly from the conveyor onto thetransverse conveyor.

As mentioned, the position of the tightenable slider 40 is adjusted sothat the amount of conveyor belt movement will be enough to stack up thecontainers, such as bottles 22, against the gates 17 or end rail 18. Theposition of the gates with respect to the first and second sides 21, 23is adjustable. The position of the end rail is adjustable also by virtueof support by rods 50 slidable in clamps 52 carried by the support frame13. This adjustability in gate and end rail position allows fordifferent sized containers to be filled. The amount of belt movementwith respect to the size of the containers being filled will depend onthe manner in which the system is being operated. As will be discussedbelow, the system can be set up so that conveyor belt movement is theprimary agent whereby containers are made to stack up in rows, oralternatively, it can be set up so that an operator pushing containersonto the feed table, consequently pushing containers ahead into theorganizer, is the primary means of pushing containers into a packedarrangement which orders them into rows.

With reference to FIGS. 1 and 2, adjustability in the set of guide rails16 is provided. The guide rails are each supported by a pair of sliders54, 56 carried by horizontal bars 58, 60 in turn supported by the frame13. The horizontal bars are provided with teeth (not shown) whichcooperate with teeth 62 incorporated in a shaft 64 extending througheach pair of sliders. By turning the shaft in either rotationaldirection the position of the guide rail associated with the pair ofsliders is adjusted in either direction transverse to the direction ofmotion of the conveyor 14. Accordingly, the width of spaces between theguide rails is adjustable to accommodate the size of the containers tobe filled. Adjacent guide rails are interconnected toward the first end21 of the feed/filler 10 by hinged plates 63 forming a collapsibleV-shape which assists in guiding containers into files in the organizer14, 16, 17, 18. Edge guide rails 65 need not be interconnected, but areadjustable as well. In an alternate embodiment (not shown) theconnection between the guide rails and the sliders 54, 56 is madereleasable so that the guide rails are interchangeable for others ofdifferent thickness.

Turning now to FIGS. 1,2 and 3 the operation of each and all of thefillers 66 of a nozzle rack will be appreciated, each being identical tothe other in the illustrated embodiment. The fillers are mounted on andcarried by a vertically moveable table 68 supported via brackets 69 andvertically actuatable rack member 71 by air cylinders 70, 72. The aircylinders move the shelf up and down thereby raising and lowering thefillers uniformly as one. The air cylinders incorporate position sensorsand provide an electronic signal that can be used to very accuratelyindicate the vertical position of the table. In one embodiment theseunits are Rodless air cylinders each incorporating a linear encoder toprovide very precise position information enabling fine control ofvertical position of the fillers. Such cylinders are commerciallyavailable, for example model no. 25-2221-20x18.12 manufactured by OrigaCorporation of Elmhurst, Ill. is used in one embodiment. In theillustrated embodiment there are 6 fillers provided. Depending on theapplication more or less fillers can be used, and the width of thefeed/filler apparatus can likewise be varied depending on the number offillers desired and size of the containers anticipated to be filled.Furthermore, the position of the table, and accordingly the position ofthe fillers, is adjustable in the transverse direction (parallel withthe direction of movement of the conveyor 14) in order to providefurther adaptability to accommodate different container 22 sizes.

Alternatively, the table carrying the fillers 66 can be actuated withthe use of stepper motors or by other servomechanisms, in any case withappropriate gears, racks, links, hydraulic actuation means, etc. andposition sensors enabling control of the vertical position. The problemof control of vertical position of the fillers, long recognized andresolved in various ways in the art, can likewise be solved in one ofvarious ways in implementing the present invention.

Each filler 66 includes a centering bell 74 which engages and aligns thecontainer to be filled with a tubular fill nozzle 67 which can extendthrough the centering bell and top opening of a container down into thecontainer, for example in performing bottom-up filling or fill-to-leveloperations, enabling a wide range of materials to be filled. Thecentering bell can be interchangeable so that it can be customized to aparticular type of container and/or filling method. As a result, a widevariety of products can be packaged using the apparatus according to theinvention. For example materials such as grease, mayonnaise, and otherproblematic materials such as foamy liquids can be filled from thebottom up. The fillers are fed from a manifold 76 connected by aflexible conduit 78 to a pump, which in one exemplary embodiment is aFDA-approved positive displacement pump 80 drawing from a day tank 82which in turn is supplied from a larger storage tank (not shown). Apressure gauge 77 is provided to monitor manifold pressure. The pump ispowered by an electric motor 84, which in the illustrated embodiment isa 220/460 volt, 3 phase, 60 cycle, wash down type. Other motor types canbe substituted. A similar motor can be used to power an air compressor(not shown) used to provide compressed air for operation of the conveyor14 and fillers 66 and gates 17 for example. Such pumps and motors arewidely available commercially. The feed/filler 10 can be equipped withtwo sets of pumps, day tanks and manifolds so that a rapid changeover inthe line is possible. For example such a redundant set including amanifold 76′, conduit 78′, pump 80′, motor 84′ and day tank 82′ could berapidly put in service to change over to filling a different productwhile the first set of components 76, 78, 80, 82, 84 is being cleanedand serviced in preparation for another production run. Accordingly theline can be kept in production nearly continuously, being down only fora brief changeover.

In another embodiment (not shown) a separate positive displacement pumpcan be employed for each filler 66. Moreover the feed/filler 10 can beadapted, with appropriate modification, to numerous fill methodologiesknown in the art, for example to: 1) a fill to a level operation; 2)laser fill to a level operation; 3) volumetric (time and pressure)filling; 4) piston pump filling; 5) net weight filling (using load cellsunder the conveyor 14 at the filler 66 location); 6) flow meter filling;as well as 7) multiple positive displacement pump filling mentioned.

The system allows for considerable variation in application. The fillers66 can accommodate filling containers 22 requiring considerable verticaltravel, this being due to the range of motion of the rodless aircylinders 70, 72. Most containers can be filled, including bottles,tubes, cartridges, as well as containers requiring pucks and othertypes. Moreover, a nozzle rack support portion 79 of the frame 13, aswell as a guide rail support portion 75, each of which is bolted to theremainder of the frame can be moved back and forth by means ofadditional bolt holes 73 provided so as to allow more or less distancebetween the fillers and the transverse conveyor 20 at the second end 23.This might be required for example if it is found that one or moreadditional rows of filled containers 22 of a given product is needed togive sufficient frictional engagement with the conveyor 14 to push theforwardmost row of containers onto the transverse conveyor as theconveyor is indexed.

Each filler 66 includes in addition to the fill nozzle tube 67 whichtravels with the table 68 sliding rods 86 which can slide with respectto the shelf. These sliding rods carry the centering bells 74 whichengage the top of each container to be filled. The sliding rods arebiased by gravity or other means such as springs or pressurized gas to afully downwardly extended position, but can retract upwardly withrespect to the table 68. As the filler descends the centering bell firstengages the container 22 to be filled. The table and fill nozzle tubecontinues to descend after the centering bell engages the container,either to the bottom for a bottom to top fill or to a level for a fillto level fill. The centering bell, restrained from further downwardmovement remains seated on the container, holding the container firmlyin place. The rods on either side of the centering bell stop theirdownward descent also, and the shelf thereafter slides down the rods.After filling the filler is retracted and pulls the centering bellupward at the latter part of its upward motion.

Each filler 66 includes a flow rate control valve 87 actuated by anadjustment knob 88 for controlling the rate of filling in all fillingmethodologies. They are particularly useful in volumetric filling wherecontrol of flow rate is critical. By adjusting the valves for aparticular flow rate at a given pressure volumetric filling can be done.These valves allow creation of a pressure differential between themanifold and each filler and compensation for pressure differential inthe manifold between the filler closest to the pump 80 and the onefarthest away for example, which might otherwise affect filling. Thesevalves can be used to fine-tune the amount of product dispensed by eachfiller during each filling cycle for example to equalize the level ineach filled container 22.

Each filler 66 also includes a valve actuator 89 which actuates a valve90 at the tip of each filler nozzle tube 67 by means of a rod 91extending through the nozzle tube. These valve actuators comprise aircylinders connected to a source of compressed air (not shown) throughconduits and control actuated valving (not shown) which applies airpressure to open or close the valve 90 by actuating the cylinder intimed coordination with other feed/filler system 10 actions. Mechanicaladjustment of the amount the valve opens is possible by adjustment ofhow far the actuator is allowed to move, to accommodate products ofdifferent viscosities for example. The valves are thus individuallyadjustable to account for small differences in individual fillers.

Each filler also incorporates a container sensor (106 in FIG. 7) forsensing if and when a container is under the filler. This is a sensorthat senses when the sliding rods 86 move with respect to the table 68as the table is lowered, indicating that a centering bell 74 hascontacted a container. If no container is under the filler when it islowered then the sliding rods for that filler will not move with respectto the table as the centering bell will not be restrained from downwardmovement by a container. In this way a controller (not shown) will bealerted that there is no container under a filler and that filler can bemade to refrain from filling.

In one embodiment for example when the sliding rods 86 move with respectto the table 68 to a predetermined point they push a flag comprising asmall metal plate 85 out of a beam of light 83 positioned to passadjacent each and all of the fillers. The flag is biased to a positioninterrupting the beam, and if even one centering bell 74 does notencounter a container 22 in position for filling the sliding rod willnot move to the preset position and the flag for that filler will notmove out of the beam and will continue to intercept the beam. If allcentering bells engage a container all flags will clear the beam and aphotosensor 81 disposed to intercept the beam after it passes all thefillers will send a signal which will indicate that all fillers havecontainers underneath, and all valves 90 can be opened to dispenseproduct. As can be appreciated in another embodiment each filler couldbe independently actuated to open and close independent of otherfillers, and an individual sensor for sensing whether a container ispositioned under each filler can be provided. Such a sensor couldcomprise for example a simple switch actuated when the sliding rod 86reaches a particular point in its upward movement with respect to thetable 68.

Filling operations are controlled and coordinated with movement of theconveyor 14. This can be done using a microprocessor-based control meansor can be accomplished with timing circuits or by mechanical means. Inany case the process proceeds in one of four ways as will be discussedin turn below.

In a first mode of operation the gates 17 are used to organize thecontainers into rows during filling operations. With reference to FIGS.4, 5 and 6, a gate 17 is provided for each file of containers at alocation just downstream of the fillers 66. Each gate is mounted on aorganizer rail 16 by means of a base plate 92 which incorporates slots93 allowing front to back adjustment in location with respect to thefillers 66. The position is set based upon the size of container beingfilled so that a mouth 93 of the container 22 will be centeredunderneath a filler nozzle tube 67 when the container is pushed upagainst the gate. All the gates are located the same distance from thefillers so that as the containers stack up against the gates they areorganized into rows. As mentioned, a nozzle rack comprising the fillers66 carried by the table 68 is also adjustable in the direction ofmovement of the containers 22 with respect to the frame 13. Accordinglythe location of filling is adjustable as well. Each gate furthercomprises a vertical member 94 carried by the base plate. The verticalmember pivotably carries an air powered piston actuator 96. The actuatoris pivotably connected to a gate member 98 in each case, the gate memberbeing pivotably carried by the base plate 90. Flexible air conduits (notshown) connect each actuator to an air valve (not shown) controlled by asystem controller (not shown) which applies air pressure to theappropriate side of each air powered piston actuator to open or closethe gate, respectively.

With reference to FIGS. 1, 2 and 3, an operator (not shown) wheninitially filling the is feed/filler 10 with containers 22 prior tostart pushes them up against the gates 17 which default to a closedposition. After commencement of filling operations the conveyor on eachstroke of the lever 26 indexes the conveyor 14 by an amount at least asgreat as the diameter 100 (or length or width for a square container)for example of a bottle plus the thickness of the gate member 98. Afterthe just-filled container passes the gate 17 it closes, pushing theempty containers back. The empty containers slide more easily on theconveyor than the filled containers, which resist slipping because ofthe weight of their contents. The filled containers push the first rowtoward and onto the transverse conveyor 20 with each indexing of theconveyor. The transverse conveyor carries them away to capping andlabeling as mentioned. The transverse conveyor can operate continuouslyor can be made to stop and start coordinated with the conveyor 14. Itmay be beneficial to start moving the transverse conveyor slowly andthereafter build up speed, being careful not to apply too muchacceleration to the filled containers, lest some of the contents sloshout. Thereafter, the operator simply loads containers onto the feedtable 12 and pushes them forward to stack up against the gates. Wings102 are provided adjacent the outer guide rails 65 to facilitate loadingand pushing empty containers up against the gates 17. In this way thegates prevent the operator from pushing containers beyond the fillers67, which can result in empty containers being pushed out onto the lineand perhaps even going out to customers.

In a second embodiment the gates 17 are used only at start up, to makesure no empty containers are passed out onto the line. Thereafter theoperator or the conveyor 14 pushes the containers up against theresistance of the filled containers at the second side 23; or,alternatively, pushes all containers, filled or empty, up against theend rail 18. The conveyor indexes by at least one diameter 100 at eachstroke in this second methodology. If the apparatus is operated in thisway the gates can be operated in a discretional mode where they close oropen by an operator manually actuating a switch, for example to hold thecontainers while several rows accumulate behind the fillers 66.

In a third way of operation the conveyor 14 pushes the containers 22against the gates 17 to organize them into rows. In this methodology theconveyor indexes by more than the diameter 100 plus the thickness of thegate member 98. The operator simply loads containers onto the conveyor,which takes them from there and packs them into rows by movingunderneath them after they are stacked up against each other. The filledcontainers also stack up against the end rail 18, preventing the secondrow and subsequent rows from advancing and reaching the conveyor untilthe first row, stacked against the end rail and positioned on thetransverse conveyor 20, is moved out onto the line.

In a forth mode of operation the gates 17 again only function at thestart of a production run to insure no empty containers 22 go out ontothe line. After starting the feed/filler the conveyor indexes by thecontainer diameter only until the first containers are up against theend rail 18. Thereafter the system operates in a manner similar to thatjust described in connection with the third way of operation but stacksthe containers up against the end rail 18, thereby organizing them intorows.

With reference to FIGS. 1 and 7 operation and control of the system inan exemplary embodiment will be described. When feed/filler 10 is loadedwith bottles, the distance the conveyor 14 will move each time it isindexed is adjusted, and filling operation parameters such as whichfillers 66, if any, are turned off, filler pump 80 RPMs, filler tube 67down speed and up speed, where to fire air cylinders comprising thefiller valve actuators 89 to open and close the valves 90 at the bottomof the filler nozzle tubes 67, final retract height for the fillernozzle tubes, and the like are entered by means of a user interface 104of a controller 105, the operator pushes a cycle start button on theuser interface. The user interface can comprise a key pad (not shown) ortouch screen or dials or other means to input information, and caninclude a display (not shown) to convey information to the operator.After entry of the parameters, or recall of a preprogrammed set ofparameters, the nozzles drop to a bottom position by actuation of avertical actuator 107 which can comprise for example the rodless aircylinders 70, 72 and valving controlled electronically. If all activefillers sense by means of container sensors 106 that a container isunder each filler the process continues. If not, the fillers fullyretract and signal the operator and wait for another cycle start signalgiven by the operator pressing for example a cycle start button on theuser interface. The filler valve actuators 89 fire and open the fillervalves 88, the pump 80 is turned on, and the containers are filled asthe nozzle rack comprising the fillers mounted on the table 68 rises bymeans of the air cylinders 70, 72. Vertical position informationconcerning the filler tubes is fed to the controller by a fillervertical position sensor 108, which in the illustrated embodiment is anencoder integral with the air cylinders comprising actuators 70, 72which move the table 68 up and down. In one embodiment a fill levelsensor 111 senses when a preselected level is reached. This can be forexample a laser sensor mounted adjacent each filler, or in applicationswhere the bottom of the fill tube can be lowered to the desired fluidlevel it can be a pressure transducer sensing a pressure change whenfluid reaches the bottom of the fill tube, for example. The pump 80 thenis stopped and the filler valves 90 close and then the filler nozzletubes 67 fully retract. The gates 17 open by means of gate actuators 109which can comprise electronically controlled air valves controlling airto and from the piston actuator 96 of the gates described above. Theconveyor 14 indexes one row of containers 22 by actuation of theconveyor actuator 112, which can comprise an electronically controllableair valve and source of compressed air as discussed above, and the aircylinder 24 shown. Then the transverse conveyor 20 is actuated by anactuator 114 which can comprise an electric motor for example, andcarries off one row of containers. The cycle repeats unless a cycle stopbutton is depressed since the beginning of the cycle, whereupon thecycle stops.

A transverse conveyor container sensor 110, comprising in one embodimenta proximity sensor sensing when a container passes, enables thecontroller 105 to sense when all six (or some other number if more orless fillers 66 are used) containers have passed out onto the line viathe transverse conveyor 20. The transverse conveyor can alternatively berun continuously or intermittently depending on the application.

In order to provide the control functions mentioned, the controller 105comprises a processor 116 interacting with the other components as shownand with a memory 118 which in a presently preferred embodiment is anon-volatile memory enabling one or more set of system set-up parametersas mentioned above to be stored. This enhances the facilitation of rapidchangeovers from one product being packaged to another. A timingfunction is also required and a clock 120 is provided. An appropriatepower supply 122 is provided.

The user interface 104 can include a display as mentioned, which can bea cathode ray tube or a liquid crystal display, which can showinformation imputed and system status for example. Operation of thesystem can be simplified by programming stored in the memory 118,allowing prompting for input of system parameters to be used orselection of a previously stored set of parameters.

As can be appreciated, considerable variation in the specifics ofimplementation of the invention is possible. As mentioned timingcircuits, with adjustment of parameters accomplished for example byadjustment of potentiometers or switches in combination with mechanicaladjustment could be used. Compressed air actuation can be replaced byhydraulic actuation. Also for example, instead of air actuation of theconveyor 14 by means of an air cylinder 24, lever 26, etc. or ahydraulic actuator, a stepper motor could be employed, or a motor andgear train with a counter which stops the motor and resets after anadjustable number of shaft rotations of the motor has been reached. Inanother possible variation a notched circular plate attached to a shaftwith a means to count the number of notches passing by a specific pointcould be employed, thereby enabling very precise control particularly ifthe shaft turning the plate is an input shaft of a gear train and theoutput shaft to the conveyor is geared down to a much lower speed ofrotation. Numerous other variations will suggest themselves to oneskilled in the art.

With reference to FIGS. 8 and 9 for example in another embodiment asecond nozzle rack 130 is provided, substantially identical to thatdescribed above and including the same number of fillers 66 mounted inline with and in mirror image relation to those described above so as tosimultaneously fill containers in another row. This second nozzle rackfor example is carried by a table 132 supported and actuated verticallyup and down by the rodless air cylinders 70, 72 as before described. Thesecond nozzle rack 130 is fed by a second manifold 76′, flexible conduit78′, pump 80′ and day tank 82′ as before described, except they can inthis configuration be run simultaneously with those same counterpartelements 76, 78, 80, 82 supplying the first set of fillers 66.

This configuration allows the option of a two-part filling operation,for example oil and vinegar in the same bottle container 22. As thebottle is moved by the conveyor 14 from the first side 21 toward thesecond 23 the fillers of the first nozzle rack 130 partially fills itwith one product, and the second nozzle rack 134 encountered fills thebalance with a second product.

The configuration would also allow the feed/filler 10 to fill twodifferent products at the same time. Each nozzle rack would have onlyhalf its fillers 66 operational, for example by closing 3 flow controlvalves 87 and disabling the sensing apparatus described above withrespect to these fillers as required. For example a first group 136 offillers would fill containers with a first product and a second group138 would fill a second product.

In this embodiment capacity can also be increased by using both nozzleracks 130, 132 simultaneously to fill the same product. In this mode ofoperation the conveyor is indexed alternately one and three timesbetween each time the fillers 66 are lowered for filling. This isbecause every other time the fillers are lowered two rows of filledcontainers will be stacked up behind the nozzle rack 134 closest to thesecond end 23, having been filled by the other nozzle rack 130 closestto the first end 21.

Also, if one row of containers 22 at a time is filled productchangeovers can be nearly instantaneous as one product can continue tobe filled through one nozzle rack 130 for example, fed by one manifold76′ for example, while the other set 134, 76 is being installed andreadied to be put into production after cleaning for example.

Furthermore in another embodiment the task of adjusting the positions ofthe guide rails can be simplified, or alternatively automated, byemploying a scheme as illustrated in FIGS. 8 and 9. Support rods 140,142, 144 are rotatably supported by guide rail support portions 146,148, 150 of the frame 13, all moveable as before described inconjunction with the nozzle rack support portion 79 of the frame withrespect to the remainder of the frame. The support rods are threaded insegments of alternating left and right turning cooperating with threadedblocks 152 likewise alternatively threaded so that as the support rodsare turned the guide rails 16, 65 are simultaneously moved closer orfarther away from each other, reversing direction with a reversal ofdirection of rotation of the support rods. This can be coordinated byproviding a shaft 154 which includes threaded segments 156 that act asworms in turning the support rods by means of splines 156 engaged by theworms. This worm-gear arrangement can be manually turned with a specialtool (not shown) or a motorized drive 160 shown schematically can beprovided, enabling the process of adjusting the guide rails tofacilitate filling a particular sized container 22 to be automated, forexample using the controller 105 mentioned above and an encoder (notshown) configured to sense position of at least one of the support railsor alternatively the amount of rotation of at least one support rail.Since all the guide rails and support rods are tied together sensing oneaccounts for all.

It will be appreciated that a feed/filler 10 according to the inventionprovides advantages in packaging products by combination of theorganizing function of a container feeder with that of a filler.Economies can be realized through elimination of waiting time forcontainers to feed in and out of a separate filler, as well as inproduct and container changeovers, for example, using equipment made inaccordance with the invention.

While certain particular forms of implementation of the invention havebeen described, it will be understood that much variation can be madewithout departing from the spirit and scope of the invention and thefair meaning of the appended claims. The scope of the invention is notintended to be limited except as set forth in the appended claims.

What is claimed is:
 1. A container feed and in-line container fillersystem, comprising: a support frame; a conveyor carried by the frame,the conveyor moving randomized containers in a first direction from afirst side toward a second side; an organizer, supported by the frame,further comprising a set of guide rails which line up containers infiles as the containers move in the first direction and a stoppreventing further motion of the containers in the first direction, thestop cooperating with the conveyor and guide rails to pack thecontainers into rows; a filler supported by the frame and positionedover the organizer, whereby containers are filled as they are organizedinto rows and files and moved through the organizer; a feed tableadjacent the first end of the conveyor; and a transverse conveyorconfigured for moving containers out from the system one row at a time.2. The container feed and in-line container filler system of claim 1,further comprising a feed table adjacent the first end of the conveyor.3. The container feed and in-line container filler system of claim 1,further comprising a plurality of fillers aligned in a first rowfacilitating filling of one row of containers simultaneously.
 4. Thecontainer feed and in-line container filler system of claim 3, furthercomprising a plurality of fillers aligned in a second row facilitatingsimultaneous filling of two rows of containers.
 5. The container feedand in-line container filler system of claim 1, wherein the stopcomprises an end rail adjacent the transverse conveyor.
 6. The containerfeed and in-line container filler system of claim 1, where filledcontainers push containers ahead onto the transverse conveyor as theconveyor is advanced toward the second end.
 7. The container feed andin-line container filler system of claim 1, wherein the stop comprises agate configured to selectively alternatively prevent and allow movementof the containers past the gate.
 8. The container feed and in-linecontainer filler system of claim 1, further comprising a first fillerpump and manifold adapted to move fluid to the filler for filling underpressure and further comprising a second filler pump and manifold,facilitating servicing the first pump and manifold while the second pumpand manifold is in operation.
 9. The container feed and in-linecontainer filler system of claim 1, further comprising adjustablesupports, carried by the frame, for the guide rails which allows foradjustment in the position of the guide rails to accommodate variationsin container size.
 10. A container feed and in-line container fillersystem, comprising: a support frame a conveyor carried by the frame, theconveyor moving randomized containers in a first direction from a firstside toward a second side; an organizer, supported by the frame, furthercomprising a set of guide rails which line up containers in files as thecontainers move in the first direction and a stop preventing furthermotion of the containers in the first direction, the stop cooperatingwith the conveyor and guide rails to pack the containers into rows; aplurality of fillers supported by the frame and positioned over theorganizer, whereby containers are filled row-by-row as they areorganized into rows and files and moved through the organizer; and, atransverse conveyor adjacent the second end of the conveyor, eachsuccessive row of containers arriving at the transverse conveyor beingurged onto the transverse conveyor by at least one row of filledcontainers behind.
 11. The container feed and in-line container fillersystem of claim 10, wherein the stop comprises an end rail adjacent thetransverse conveyor.
 12. The container feed and in-line container fillersystem of claim 10, wherein the stop comprises a gate for each fileconfigured to selectively alternatively prevent and allow movement ofthe containers past the gate.
 13. The container feed and in-linecontainer filler system of claim 12, wherein the gate is carried by aguide rail.
 14. The container feed and in-line container filler systemof claim 10, further two filler pumps and two manifolds supplyingproduct to be filled into the containers to the fillers, whereby onepump and manifold can be serviced while the other is in operation. 15.The container feed and in-line container filler system of claim 10,further comprising a microprocessor-based control system facilitatingcontrol of container feed and filling operations according topre-selected process step parameters.
 16. The container feed and in-linecontainer filler system of claim 10, wherein the position of the fillerwith respect to the second side is adjustable, so that the distance fromthe filler to the transverse conveyor is variable.
 17. The containerfeed and in-line container filler system of claim 10, wherein a distancebetween the filler and the transverse conveyor will accommodate at leasttwo rows of containers fillable by the system.
 18. A container feed andin-line container filler system, comprising: a support frame a conveyorcarried by the frame, the conveyor moving randomized containers in afirst direction from a first side toward a second side; an organizer,supported by the frame, further comprising a set of guide rails whichline up containers in files as the containers move in the firstdirection and a plurality of gates comprising a stop alternativelyallowing and preventing further motion of the containers in the firstdirection, the stop cooperating with the conveyor and guide rails topack the containers into rows; a feed table adjacent the first side ofthe conveyor; a plurality of fillers supported by the frame andpositioned over the organizer, whereby containers are filled row-by-rowas they are organized into rows and files and moved through theorganizer; and a transverse conveyor adjacent the second end of theconveyor, each successive row of containers arriving at the transverseconveyor being urged onto the transverse conveyor by at least one row offilled containers behind.
 19. The container feed and in-line containerfiller system of claim 18, further comprising a positionally adjustableend rail adjacent the transverse conveyor and an adjustable set of guiderail supports facilitating adjustment of the spacing between guide railsallowing the filling of different sized containers with the system. 20.The container feed and in-line container filler system of claim 18,wherein a distance between the fillers and the transverse conveyor is atleast as large as needed to accommodate two rows of containers fillableby the system.